Motor Spray Ring Nozzle Layout for Stator and End-Winding Cooling
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Solution Overview
Problem
Existing electric motor coolant systems inadequately cool certain components due to their arrangement outside the coolant flow path, leading to temperature disparities among motor components.
Innovation Solution
A unitary motor spray ring is formed via injection molding with axial grooves and nozzle orifices, guiding coolant effectively towards the stator and end windings through nozzle guide surfaces, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant flows through conventional cooling channels, then cooling coverage is limited to components within the flow path, but components outside the flow path are inadequately cooled
Solution Approach 1:
The patent employs a spray ring with multiple nozzle orifices that direct coolant sprays onto specific motor components. This hydraulic approach uses pressurized coolant delivered through nozzles to achieve targeted cooling of components like the stator and end windings, which were previously inaccessible to conventional flow path cooling
Solution Approach 2:
The spray ring configuration provides localized cooling by directing coolant sprays at specific high-temperature components. Each nozzle is positioned to cool particular areas such as the stator core and end windings, allowing different regions of the motor to receive customized cooling based on their thermal requirements
2Adaptability or versatility
If multiple separate cooling components are used to cool different motor parts, then cooling coverage is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The spray ring integrates multiple cooling functions into a single component. It combines multiple nozzle orifices, coolant distribution channels, and mounting features into one unified structure that can cool multiple motor components simultaneously, thereby reducing the number of separate cooling parts needed
3Manufacturing precision
If traditional manufacturing methods are used for the spray ring, then manufacturing precision is adequate, but manufacturing cost and production time increase
Solution Approach 1:
The patent transitions from mechanical machining to additive manufacturing for spray ring production. This manufacturing parameter change enables complex three-dimensional nozzle geometries and internal channel structures to be created directly from digital models, achieving high precision while reducing tooling costs and production time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves the cooling of the stator and end windings, increasing the motor's performance and durability while reducing manufacturing costs and weight.
Implementation Method 1
the coolant may flow across several surfaces of the motor to absorb heat from the motor surfaces
Implementation Method 2
heat produced by a motor is transferred from the motor to the coolant
Data Source
AI summary
Various systems and methods are provided for an electric motor of a vehicle, and particularly to an electric motor including a coolant spray ring. In one example, a method of manufacture comprises forming, via injection molding, a unitary motor spray ring including a plurality of axial grooves joined to a plurality of nozzle orifices.